Introduction to PDC

PDC Cutter Development

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 May not be disclosed, used or reproduced without written permission from Smith International, Inc.
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Better order for pressing
Manufacturing
Substrate, cabide defn, show interface
FEA - 3d pic
Impact vs abrasion two arrows?
No pic of testing if show video
Explain tec
Explain NPI progression
Don’t talk about HOT
More logic and flow
Leaching – get Reed Patent
Quick and Arrow – more info, should we push it
Too much field info
Objectives

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• PDC Cutter Manufacturing Process

• PDC Thermal Stability

• Cutter Design with Finite Element Analysis (FEA) &

Development of the Non-Planar Interface (NPI)

• GeoDiamond Premium Cutters

• HOT™ Cutters
 Hardness values of Hard Materials

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Hardness, HK*

0 1000 2000 3000 4000 5000 6000 7000 8000

Diamond 7,000

Cubic Boron Nitride 4,700

Vanadium Carbide 2,500

Silicon Carbide 2,400

Aluminum Oxide 2,100

Tungsten Carbide 1,900

Zirconium Oxide 1,500

Hardened Steel (65 HRC) 825

Ferrite 550

Soft Steel (85 HRB) 185

*HK: Knoop Hardness. Same hardness test as HV (Vickers Hardness) except using different indenter
Natural and Manmade Diamond

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There is only one natural environment in which diamonds can
be formed:

• Carbon (Graphite) contained in molten rock (magma)

• Under very high pressure (75 to 120 miles below earth’s surface)
• At temperatures in excess of 2,190°F (1,200°C)
• Millions of years

To manufacture diamond, man mimics nature:

• Graphite is subjected to ~1.5 million psi and ~2,200°F in the presence

of a catalyst (cobalt, nickel) to replace time, and manmade diamond
grit is produced
Manufacturing Diamond

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Graphite 1,500 - 2,800°C

Nickel or
Cobalt as
catalyst

Graphite

Manmade
Protective holder Diamond
BELT PRESS Grit
1.2 - 1.8 million psi

Note: Stone size is controlled by pressing time. Large stones require more time,
hence they are more expensive.
High Pressure Presses

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PDC cutters are manufactured using the same type of press used
to make Diamond grit (Belt, Cubic or Piston presses).

Radial
Belts Anvil Cell Anvils pressure Anvil

Die Cell Cell

Belt press Cubic press Piston press

2,150° F
Cubic Press Technology

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 Cubic Press Technology

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PDC Cutter Manufacture

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Diamond grit, having
predetermined particle size, is
placed in a refractory metal can.

The can is made from Zirconium or

Molybdenum that has high melting
temperature.

The shape of the can determines

the final shape of the compact.
PDC Cutter Manufacture - Assembly

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A Tungsten Carbide substrate is placed on top of the Diamond grit and the bottom
of the can is put in place.

The can is then mechanically sealed.

The can is placed within a graphite heater tube with salt rings used to insulate the
can from the electrical current used to provide the necessary high temperature.

Several PDC components may be produced per press cycle depending on the size
of components.
PDC Cutter Manufacture - Assembly

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Carbide Carbide
Substrate Substrate

Refractory
Metal Can
Manmade Diamond Manmade Diamond
Powder Tapes

Powder Assembly Tape Assembly

PDC Cutter Manufacture - Assembly

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SGM Cylinder

Steel Current Ring

Mica Baffle
Steel Current Discs

Salt

Assembled Part
Synthetic Gasketing
Material (SGM)
Graphite Heater
PDC Cutter Manufacture

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
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The Assembly is placed in the Diamond press.
At 1,000,000 psi and 1,400°C Diamond-to-Diamond bonding occurs.

Tungsten Carbide Diamond ~1,000,000 psi and ~1400° C

Substrate (WC) and Grit
Cobalt (Co)
Thermally Stability Polycrystalline (TSP)

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PCD thermal stability is enhanced by leaching
out the Cobalt with acid.

With the absence of Cobalt, PCD is thermally

stable to a temperature of ~1,200°C and
therefore called ‘TSP’.

TSP is then cut up into the desired shapes and

sizes depending on the proposed application.

TSP is not “wettable” therefore it cannot be

bonded to a support material limiting their
application.
PDC Cutter Development

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PDC cutter development is crucial to bit optimization

Cutter characteristics directly impact bit performance

and durability
• Impact & Abrasion resistance
• Shear strength
• Thermal stabilization
PDC Cutter Development

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Finite Element Analysis (FEA): Development Tool.

• Reduces Stress in cutters

• Enables increased diamond table thickness

.025”- .030”
.080”- .150”

Conventional New Technology

 Diamond

Tungsten Carbide Substrate

FEA Simulation: Flat Interface
Tension

Compression

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 Diamond
Diamond

Stress Reduction
FEA Simulation: Non-Planar Interface
Tension

Compression

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 Diamond
Diamond

Stress Reduction
FEA Simulation: Non-Planar Interface
Tension

Compression

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 Diamond
Diamond

Stress Reduction
FEA Simulation: Non-Planar Interface
Tension

Compression

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PDC Cutters Diamond Grades

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CONFIDENTIAL: For Internal Use Only.
Fine grain Med grain Coarse grain
Higher abrasion - Low impact Moderate abrasion - Med. Impact Low abrasion - High Impact

1 - 6 microns 7 - 15 microns 16+ microns

 t
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I

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c

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a
p

S
m

Grain Size
Impact Strength

Abrasion Resistance
i
i

t
r

c
s
s
s

e
n
a
e
n
o
a
b
A

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Effect of diamond size on cutter properties

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 Premium PDC Cutters

CONFIDENTIAL: For Internal Use Only.

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
Premium PDC Cutters

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
• We have Engineering Cutters and Premium Cutters

• Engineering Cutters are cutters in development and

testing stage. Once they are tested to perform well
(lab and field tests), they are promoted to premium
cutters.
Premium
Yes Cutter

Field Tests OK?

Yes

New PDC Cutter PDC Cutter No

OK?
“Engineering Cutter” Mechanical Tests
No
Rejected
 • Impact: Drop Tower Test
PDC Cutter Mechanical Testing

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May not be disclosed, used or reproduced without written permission from Smith International, Inc.
 • Abrasion: Granite Log Test
PDC Cutter Mechanical Testing

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 • Abrasion: Mill Test Machine
PDC Cutter Mechanical Testing

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 Adjusted LOC (in)

Mill Test
Premium Cutter Scores

Note: HOT cutter has .100” Depth of Cut instead of the standard .080” for Cold Cutters

CONFIDENTIAL: For Internal Use Only.

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 Low Energy Impact Test
Premium Cutter Scores

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May not be disclosed, used or reproduced without written permission from Smith International, Inc.
 Premium Cutter Scores
High Energy Impact Test (10J)

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 Premium Cutter Scores
High Energy Impact Test (20J)

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 Premium Cutter Scores
High Energy Impact Test (30J)

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May not be disclosed, used or reproduced without written permission from Smith International, Inc.
 Premium Cutter Scores
Field Recommendations (HOT Cutters)

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May not be disclosed, used or reproduced without written permission from Smith International, Inc.
 GXT Cutters

GG (GeoGrid)
Premium PDC Cutters

GMX (GridMax)

Development Timeline
GXT

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 Premium PDC Cutters

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
GXT Evolution
GridMax (1998) 0.120”DTT GXT (2001) 0.120”DTT
GeoGrid [3rd Generation] (1997) Multiple iterations in Multiple iterations in
0.080”DTT interface and diamond interface and diamond
Multiple iterations in interface and
diamond

Early Version

GXT(#)-J (2002) 0.120”DTT

GridMax-J (2001)
GXT(#)-JV2 (2002) 0.120”DTT
0.120”DTT

GXT(#) –J
GeoGrid GridMax GridMax-J GXT(#)
GXT(#)-JV2
1308, 1313, 1308, 1313, 1316 1308, 1313, 1316 1916 1916
1316 1913, 1916 1908, 1913, 1916 2213 2213, 2216 Current Version
1908, 1913, 2213, 2216
1916
Premium PDC Cutters

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
SXT Cutters

Sonic SMX (SonicMax) SXT

Development Timeline
Note: This whole family of cutters is always a one piece design with no LS bond line
Premium PDC Cutters

SXT Evolution
Bulls Eye (Pre 1998)
Multiple iterations in
interface and diamond
May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
Sonic (1998) 0.080”DTT
Multiple iterations in
interface and diamond

SonicMax (1999) 0.120”DTT SXT (2001) 0.150”DTT

Multiple iterations in Multiple iterations in
interface and diamond interface and diamond

Interface Progression
Sonic
SXT-A (2001) 0.120”DTT

SonicMax Sonic SonicMax SXT SXT-A SXT-J

1608, 1613, 1308, 1313, 1613,161 1313, 1613,
1616 1316 6 1316 1616
SXT
1613,1616 1613, 2213,
1616 2216
TEC
.030”
TEC Cutter
Premium PDC Cutters

.065”

TEC - S
.120”

TECMax

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 Wear

4
TEC Operation
Premium PDC Cutters

Bit Life (hrs)

Conventional
TEC

Additional Life

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 Premium PDC Cutters

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
TEC Evolution

TECMax Worf II (1999) 0.100”DTT

TEC (1998) 0.070”DTT
TECMax Worf I (1998)
TEC-S (1998) 0.070”DTT 0.110”DTT
Multiple iterations in
diamond Quasar Worf II (2001) 0.070”DTT
Only Saw Limited Use

Dimpled Tier (2001) 0.160”DTT DXT (2002) 0.150”DTT DXT-J (2002) 0.125”DTT
Never a standard product Multiple iterations in DXT-J2 (2002) 0.130”DTT
interface and diamond

DXT-J
TECMax W2 Quasar DXT DMX
DXT-J2
0906,0911,0913 0906, 0911, 0913 1313, 1316 1313, 1316 1313
1108, 1113, 1116 1313, 1316 1613,1616 1613, 1616 1613, 1616
Early Version
1308, 1313, 1316 1613, 1616 1913, 1916 1913, 1916 1913, 1916
1608, 1613, 1616 2213, 2216
1913, 1916

UINTA Cutter (2003)

0.110”DTT
 New D20

Availability: 16mm
Diamond Table: 0.100”
Premium PDC Cutters

Similar properties to those of D12

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 Premium Cutter Scores

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May not be disclosed, used or reproduced without written permission from Smith International, Inc.
Premium Cutter Availability

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
• D10:  11mm, 13mm, 16mm and 19mm

• D11:  16mm

• D12:  9mm, 11mm, 13mm, 16mm and 19mm

• TMX:  9mm, 11mm, 13mm, 16mm, and 19mm

 Cutter Optional Features

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Quick™ Cutters

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
Engineered relief in the substrate.

Geometry increases cutter penetration.

Requires less energy to achieve

efficient DOC.
• WOB to initiate shearing and Torque
requirements are reduced.
Quick™ Cuttes

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
Very low rates of wear flat generation.
Stays sharp longer.
Extends bit life.
Application Specific

Wear Wear
Flat Flat
A1 A2
Carbide drag area of GeoMax-Quick cutter (A2) is much lower than that of a
conventional cutter (A1) without the relief.
 Quick™ Cutters Installed in a Bit

CONFIDENTIAL: For Internal Use Only.

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
Arrow™ Cutters

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
Arrow cutters have a pointed
edge.

Cutter purpose is to pre-fracture

rock.

This specialized cutter is

recommended only for
carbonates.
 HOT™ Cutter Development

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What are HOT™ Cutters?

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CONFIDENTIAL: For Internal Use Only.
High Operating Temperatures (HOT) cutters are cutters with
significantly improved wear resistance for improved footage and
penetration rate in applications where the primary failure mode
is cutter wear (for example, when drilling abrasive sandstone)

Furthermore, since HOT cutters have an improved ability to run at

high operating temperatures, they can also extend bit life when
high energy (e.g. high WOB/RPM) is run on PDC bits in mixed
lithology drilling
 How Do HOT™ Cutters Work?

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HOT™ Cutter Development

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CONFIDENTIAL: For Internal Use Only.
“A” Cutters
(High Abrasion) HOT
Abrasion Resistance

Very thick diamond Large diamond grain

table, medium grain size, optimal
size. Example: 13mm Standard Cutters
diamond table
(Med````
Abrasion
SXT-A ET Med Impact) thickness. Example:
13mm GXT3-JV2
Medium abrasion and Impact
properties with various “J” Cutters
combinations of diamond grain size, (High Impact)
depending on cutter type, with
optimized diamond table thickness

Impact Resistance
Field Tests

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CONFIDENTIAL: For Internal Use Only.
Test Objectives
7 ⅞” M616VPX - JT1345
Minimize cutter wear / breakage
Improve ROP and footage drilled
Better Dull condition
Minimize rebuild cost

Results:
Improved ROP by 15%
Increased footage drilled by 50%
Unit Drilling, Rig # 22
Dull condition Improvement Burlington Resources,
Roger Mills County, OK
 7 ⅞” M616VPX, JT1345
“HOT Cutters”

May not be disclosed, used or reproduced without written permission from Smith International, Inc.
CONFIDENTIAL: For Internal Use Only.
Standard Cutters
31-15N-22W 9-14N-21W
USA #7-31 LORENA #7-9
DEPTH IN: 9,004’ DEPTH IN: 8,941’
DEPTH OUT: 10,970 DEPTH OUT: 11,823’
FOOTAGE: 1,986’ FOOTAGE: 2,882’
HOURS: 50.0 HOURS: 62.5
ROP = 39.72 ROP = 46.11
1-3-WT-A-X-X-X-IN-SP-PR 0-1-WT-S-X-X-X-IN-SP-FM
Standard
Standard
7 ⅞” M616VPX, JT1345 - BLADE #1

7 ⅞” M616VPX, JT1345 - BLADE #6

“HOT”

“HOT”

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Field Tests

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CONFIDENTIAL: For Internal Use Only.
8 ¾” MA619PX, Tyler, Texas

Std Cutters HOT Cutters

Depth Out: 6,264ft Depth Out: 6,286ft

Drilled 4,819ft in 53.5 hours Drilled 4,930ft in 44.5 hours

Penetration Rate 90.0 ft/hr Penetration Rate 110.8 ft/hr

 Congratulations to the Drilling Team of:

Bravo Nat. Res.

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CONFIDENTIAL: For Internal Use Only.
Operator/Contractor Representatives:

President: Charlie Stephenson

Consultant: Lenard Nunley
Tool Pusher: John Scott
Deepest/Fastest 7 ⅞’ PDC bit run in Wheeler County

1,245’ to 7,491’ (6,246’ in 85.5 rotating hours)

Rig: Patterson/UTI Drilling #405

Well: Atherton 2-69
County: Wheeler
State: Texas
Field: Granite Wash

7 ⅞” M72VPX
S/N: JT2017
Field Tests
7 ⅞” M87PX, Tyler, Texas

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CONFIDENTIAL: For Internal Use Only.
Std Cutters HOT Cutters

Depth Out: 7,210ft Depth Out: 7,212ft

Drilled 5,404ft in 80.0 hours Drilled 5,356ft in 72.5 hours
Penetration Rate: 67.6 ft/hr Penetration Rate: 73.9 ft/hr
 Review

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CONFIDENTIAL: For Internal Use Only.
1) Mention raw material and conditions to manufacture Polycrystalline
Diamonds (PCD):

Material:
Temperature:
Pressure:

2) TEC cutters are more impact resistant

T F

3) To manufacture HOT PDC cutters we remove:

a) Tungsten Carbide
b) Carbon
c) Cobalt
d) Nickel